Strategies for Developing New Membrane Separation Processes

The presentation will provide an overview of strategies for developing new membrane based separation processes using a three step process. The first step is to identify and characterized the components present in the feed material including the physiochemical properties of the target material and contaminants as well as an assessment of potential interactions between the target material and contaminants. The second step is design a preliminary separation scheme including and assessment of the pore size requirements, membrane type, and spacer geometry and size. The final step is to conduct laboratory and pilot scale testing.

Fundamental Principles of Membrane Separations in the Food Industry

Wasted time and financial resources can be minimized when fundamental principles are used to properly design and operate membrane systems. This presentation will review the fundamental principles that govern membrane separation processes in the food industry, with a focus on dairy products. Effects of membrane module design, recirculation loop flow rate, and permeate flux control will be reviewed. Flaws in existing membrane system design and operation will be highlighted with suggestions for future improvements. Recent advances in membrane technology will be reviewed. Novel food protein ingredients made possible by new membrane technology will be recounted. Membranes have revolutionized the food processing industry since they were first introduced in the 1970s. Advances in membrane manufacture and processing technology, if widely adopted by industry, will lead to further major improvements. We are wise to remember a quote from Steve Jobs: “Innovation distinguishes between a leader and a follower.”

PFO Technology and Applications

Porifera’s PFO products are ideal for concentrating streams with high osmotic pressures and suspended solids in both food and beverage processing, such as fruit juice, coffee, and dairy for example, and as well as waste processing. Porifera’s innovations include a new high flux, high selectivity forward osmosis (FO) membrane combined with a new element design for FO processing. The advantages of Porifera’s PFO technology include low head-loss, reduced footprint, and both co-current and counter-current processing. Porifera has also developed FO membrane systems with draw recovery for high osmotic pressure processing, competing with thermal evaporators. This talk will provide latest information on Porifera's PFO technology and applications, and discuss results of Porifera's recent commercial activities in food and beverage processing.

Utilizing Data Mining and Process Modeling to Promote Food Safety, Product Quality, and Improve Membrane System Performance.

This presentation will provide an overview of new technologies being utilized to capture and process data from membrane systems in CIP and production modes. The raw processing and CIP data is treated using analytical software and reporting tools to benchmark performance and highlight anomalies. The reported, actionable information increases visibility with the end result being an enhancement in food safety, product quality, and operational efficiency.

Quantitative Differentiation of Crystar FT vs Oxide Membranes in Crossflow F&B Applications

The presentation will focus on the inherent benefits that Crystar FT recyrstallized silicon carbide (R-SiC) ceramic membranes have versus oxide ceramic membranes in crossflow configuration. The first part of the presentation will highlight inherent material advantages of Crystar FT R-SiC membranes vs oxide membranes, while the second part of the presentation will show food and beverage application examples where these inherent advantages are observed. Saint-Gobain's Crystar FT recrystallized silicon carbide (R-SiC) membranes are within the microfiltration (MF) range and are constructed in both crossflow and monolithic dead-end configurations for use across both water/wastewater and industrial processes and life sciences applications.

Pilot Testing of Cold Concentration and Inside Membranes in Food and Beverage Processing

The past years we introduced the concept of using aquaporin water channels as highly selective and efficient water transport components in a new type of membrane. After the introduction of low pressure reverse osmosis membranes for tap water applications, Aquaporin A/S also specializes in cold concentration, a water extraction process based on osmosis. Here, an osmotic pressure difference is used instead of hydraulic pressure or heat to remove water gently from a feed stream. In this year’s talk we will focus on taking the step from concept in the lab to piloting on site by introducing a 6x increase in membrane area to reach an industrially relevant module size. With its help, the concept of cold concentration of highly valuable feed streams, containing components like nutrients and aromas, will be shown and discussed in a more industrial setting. This will include scaling effects, cleaning experiences and full scale feasibility estimations.

Membrane System Troubleshooting and Diagnosis

In this year’s instruction, I will discuss the basics of membrane system operational failures and how to best diagnose and troubleshoot these situations. Attention to membrane failures, tools, remedial strategies and the membrane warranty process will be discussed.

Energy Reducing Innovative Feed Spacer

In many membrane filtration systems a reduction in cross flow resistance will lead to a reduction in the energy consumption of that system. The ASD (Alternating Strand Design) technology by SWM is an innovative and new RO feed spacer that has been developed with this energy reduction in mind. Initial design work was done using 3D CAD and Computational Fluid Dynamic (CFD) modeling to determine the optimum size and shape of the netting strands. Once the final design had been established, a 3D printed prototype of the feed spacer was produced. The prototype feed spacer was then tested in a benchtop cross-flow tester to evaluate the improvement in pressure drop. ASD technology has been successfully commercialized for use in spiral wound reverse osmosis (RO) elements and is demonstrating significant energy savings in end use applications.

The Future of Automation

Without the development of structures and data links, the interpretation of data from several systems is impossible. ProLeiT achieved this with a PCS combining a complete horizontal and vertical integrated automation solution, with a special focus on plant data to bridge the gap between these layers. Building on our previous presentation, we’ve had success with the Smart Factory model- a group of customer plants with uniform data, allowing direct comparisons. Predictive Analysis uses relevant data to extrapolate trends, proactively mitigate risks, and capitalize on hidden opportunities. Plants already collect data, but these parameters must be pre-configured; without the appropriate data, organized in an applicable context, the potential value of these efforts are lost. Filtered analyses of every data point guarantees the best possible quality, the least wasted resources, with reports to back it up. Now, with the evolution of PCS, reports can help identify key processes capable of optimizing production, predicting failures, and preventing downtime while concurrently reducing raw material, energy, utility, and equipment usage. Practical applications for our customers:

• Constantly monitoring performance
• Product quality, consistency
• Proactively mitigating failure
• Efficiently timed cleaning cycles
• Accurately identifying and optimizing OEE and KPI factors
• Optimized parameters - each product and piece of equipment

Vital Contributions of Membrane Technology in the Processing of Polyphenol-rich Foods

Polyphenols are the most common phytochemicals in human diet. Polyphenol-rich foods are considered to possess antioxidant, antimicrobial, anticancer and anti-inflammatory properties. Flavonoids are the largest group of phenolic compounds and are found in various fruits, vegetables, tea and coffee. Membranes are used at several junctions during processing of polyphenols be it for clarification to remove suspended and precipitated solids, to purification and fractionation of polyphenols and finally for concentration before drying.

Novel Food Processing Applications for Spiral-wound Membranes

Reverse Osmosis, Nanofiltration, and Ultafiltration membranes are used in the food and beverage industry for a variety of applications. Reverse Osmosis can be used to concentrate or de-water process streams. Nanofiltration membranes are designed specifically for separation of divalent anions and / or organic molecules from monovalent salts and lower molecular weight organics. Ultrafiltration can be used to concentrate high molecular weight compounds. Applications include: whey and milk concentration, de-salting (mineralizing) of whey and other streams, DP1 / DP2 sugar fractionation, BOD / COD reduction applications, casein and whey protein concentration, and enzyme concentration. This presentation will examine critical issues in the application of spiral wound membranes. Case studies from operating units will also be presented.

Accelerating Innovation in Dairy Applications of Membrane Processing

The panel will discuss innovations from a membrane manufacturer's perspective, how innovations are growing around the world, as well as the challenges of applying these innovations in dairy plants.

Whole Milk Microfiltration for Cheddar Cheese Make & Evaluation and Ultrafiltration without MF to Produce Heat Stable WPI

For several years, the UW Center for Dairy Research (CDR) has been routinely conducting Milk Microfiltration research for peer reviewed publication and confidential industry clients. The latest MF research microfiltrated whole milk to evaluate the process and composition compared to control milk. Two levels of casein and three ratios of casein percentage of protein were evaluated. The second half of the title involves on going research to make heat stable whey protein isolate (WPI) without utilizing microfiltration. UF is utilized to thoroughly demineralize whey, which allows for effective sedimentation of the fat and any denatured protein in one step before completing the final concentration step and spray drying. Interestingly, MF is not utilized to achieve WPI composition. The CDR is well equipped to conduct controlled research using large scale, processing equipment to fractionate, concentrate and then spray dry or utilize as fluid ingredients, dairy protein products with unique composition and functionality. CDR has the staff and infrastructure resources to utilize those protein products in consumer product applications and to evaluate the range of analytical, physical and sensory attributes. CDR staff routinely present at industry conferences across the nation including to co-host the Wisconsin Cheese Industry Conference and International Cheese Technology Expo. Additionally CDR offers multiple dairy processing short courses that cover dairy process equipment demonstrations complimented by technical power point presentations given in UW classroom settings.

Process control for a more efficient membrane filtration/concentration process

One of the major issues in membrane operation is the membrane fouling. Monitoring in real time the membrane separation efficiency makes it possible to optimize the process operating conditions, in terms of flow rate, pressure or even temperature, and will prevent accelerating the fouling phenomenon. The resulting benefits are the production capability, maintenance cost optimization, and energy cost savings.

Membrane and Module Modification for Enhanced Spiral Wound Performance in Dairy Processes

The measured impact of individual improvements in spiral wound module construction can be combined and utilized for optimizing element performance in the field, in the interest of increasing yields and improving product quality and value. The objective of this presentation is to review key aspects module composition that were subject to modification and evaluate their measured contribution to element performance in the field. These methods include new crease protection techniques for better solids loading and material selection changes made with the objective of maximizing product throughput. Additionally, membrane optimization techniques for improved separation performance, including necessary considerations in membrane selection criteria for MF, UF, and NF, are reviewed.

Harnessing Super Foods from Africa

The goal is to provide information on proven solutions to optimize the use of super foods from Africa in food and beverage products through innovative, collaborative, and dynamic partnership with farmers and herbalists in rural communities. Driven by both the need for wholesome food choices that can help people live longer and healthier, my goal is to provide information on proven solutions to optimize the use of super foods from Africa in food and beverage products through innovative, collaborative, and dynamic partnership with farmers and herbalists in rural communities. I will be presenting the several approaches and tools to help western industries harness the super foods from Africa, in a way that enhances their products and provide more innovative approaches to obtain insights into rare herbs and plants that can be used in the food and beverage industries. In this presentation, I will demonstrate several research specimens, their effects on improving health and how a company can collaborate in a unique and dynamic partnership with indigenes and farmers to enhance the feasibility of harvesting and using some of these rare plants in their organizations. I will explore the challenges and present examples of the value in harnessing these foods, and ultimately the possible result for both the communities, companies, and consumers.

Wastewater Treatment Processes for Recycle and Reuse in Food and Dairy Applications

More and more often, dairy and food processing facilities are challenged with tighter wastewater regulations and water scarcity. As incoming water quality has become less reliable and companies search for more sustainable processes, multiple technologies are being put in place to take wastewater from these plants and treat it to a reusable state. KMS would like to present an overview of the key steps needed to treat Food and Dairy process wastewater from influent to reusable water quality. We will highlight the different technologies associated with this treatment and discuss the regulatory challenges that can accompany these types of projects.

Outside of the factory doors - Membrane Bioreactor vs. Conventional Industrial WW Technologies

This presentation is about a comparison of membrane bioreactor vs. conventional industrial wastewater technologies. Following a brief introduction into the general theory of biological wastewater treatment, several commonly employed process configurations are presented. As direct discharge effluent limitations become more restrictive and the cost of discharge to municipal sewage treatment plants increases, the number of industrial MBR systems in use has increased. The data base for comparison with “conventional” WW treatment technologies has steadily expanded. The comparison will adress 4 areas: effluent quality required for comparison, capital cost, operating cost, reliability. Aerobic and Anaerobic MBR full scale operating examples are presented to further support the comparisons of the presentation.

Implementation of Low Effluent Processes for Whey Demineralization

For more than thirty years, Eurodia Industrie (and its US subsidiary Ameridia Innovative Solutions Inc.) has been successfully developing and installing process lines for the production of demineralized whey products of all grades to meet the most demanding specifications of the end users. This includes Demin. 90 for the production of instant formula, for which the production of the Eurodia customers represents almost 70% of the world market. These demineralization lines combine Ion Exchange resins, Nanofiltration, and Electrodialysis. One of the increasingly tight constraints is the minimization of effluents out of the process lines. Extensive attention has been continuously given to optimally reuse various streams to lower the effluent load. However, over the last few years, the need to practically eliminate all effluents has led to the implementation of additional membrane process steps to enable the recycling of most streams, even the salts that have been removed from the whey. This presentation will focus on these innovative membrane techniques and how they have significantly reduced the effluent load for the Eurodia most recent whey demineralization projects.

Evaluating Total Cost of Ownership with Membrane Systems

The use of ultrafiltration for the production of whey and milk protein concentrates is well practiced. As with any investment, total cost of ownership (TCO) should be evaluated when making decisions on how your UF system is designed, built and operated. The main components of TCO for a membrane operation typically are: capital, energy consumption, water usage, cleaning chemicals and membrane replacement. Protein capture is not always considered in the TCO process, so decisions can be sub-optimal. Why would I buy a larger, more expensive system? Why would I spend more money on cleaning chemicals? Why would I replace elements more frequently? The answer to all of these questions…to optimize total cost of ownership.

Best Practice Measurements and Control Points to Ensure Maximum Efficiency of Membrane Systems

Efficiency and operational life of a membrane system relies on the right selection, sizing, installation and configuration of critical measurement points such as pressure, mass or volume flow, density and/or concentration measurements. The presentation will help you understand:

• Typical measurement points for control and monitoring
• Understanding the measurement principles function, capabilities and limitations
• Selecting the right instrument

Main focus will be on:

• Coriolis Massflow/density
• Magnetic Flow
• Optical Density and
• Refractometers Pressure

The Obvious Choice - Two Case Studies of Ultrafiltration in Dairy Wastewater

The use of membranes for dairy wastewater will be explained and compared for two new construction dairy sites using two types of ultrafilter membranes. Membrane separation was chosen to meet tight limits for direct discharge in sensitive waterways at both sites and as a source for reuse water at one of the sites. The choice of membrane types was based on available footprint, speed of implementation and differing operational characteristics. Performance data and preventative maintenance history indicate the facilities perform very well and are easy to operate. Startup and operational difficulties with the facilities and with membranes in general will be discussed along with criteria to choose one membrane type over another. How the membranes were integrated into the wastewater processes will be presented along with options for high strength wastewaters.

Common System Operation and Engineering Issues

Membrane systems process a multitude of products and come in many configurations. Regardless of the various system designs and uses they typically suffer from common issues. Often times there is a lack of understanding of optimal system operation and tools to identify or fix these issues at the plant level. In this presentation we are going to focus on common issues in plant design such as undersized utility systems and non-optimal installations that result in underutilization of the membrane equipment and identify the tools that can be used to identify, assess, and counter these issues.

Effluent Treatment in AgroIndustries Using Ceramic Membranes

The treatment of remaining tests from biogas production (digestion) is a severe problem in some areas in Europe. Treatment is very complex and requires several unit operations, including ceramic membranes. The purpose of this treatment is a reduction of volume and thus increase efficiency for transportation and volume reduction. The whole process will be described including some examples.